Crankcase ventilation filter assembly; components; and methods

ABSTRACT

Crankcase ventilation filter arrangements and components therefore are described. Example arrangements are described. In one, a serviceable filter cartridge includes a check valve therein, for protection during vehicle rollover. Handle arrangements are also described. Methods of use are described.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Ser. No. 12/452,970, filedSep. 22, 2010. U.S. Ser. No. 12/452,970 is a US National Stage of PCTInternational Patent application No. PCT/US2008/071783, filed 31 Jul.2008, and claims priority to U.S. Provisional patent application Ser.No. 60/962,993, filed Aug. 2, 2007; each of U.S. Ser. No. 12/452,970;PCT/US2008/071783; and, U.S. Ser. No. 60/962,993 being incorporatedherein by reference. To the extent appropriate, a claim of priority ismade to each of the above disclosed applications.

FIELD OF DISCLOSURE

This disclosure relates to systems and methods for separatinghydrophobic fluids (such as oils) which are entrained as aerosols, fromgas streams (for example air streams). Further, the arrangements alsoprovide for filtration of other contaminants such as carbon material,from gas streams. The arrangements are typically used to filtercrankcase ventilation gases from engine systems. Methods for conductingthe separations are also provided.

BACKGROUND

Certain gas streams, such as engine blow by gases (i.e. crankcaseventilation gases from the crankcases of diesel engines) carrysubstantial amounts of entrained oils (liquid) therein, as aerosol. Insome instances. many of the oil (liquid) droplets within the aerosol arewithin the size of 0.1-5.0 microns.

In addition, such gas streams also carry substantial amounts of fineparticulate contaminants, such as carbon contaminants. Such contaminantsoften have an average particle size within the range of about 0.5-3.0microns.

In some instances, it is desired to vent such gases to the atmosphere.In general, it is preferred that before the gases are vented to theatmosphere, they be cleaned of a substantial portion of aerosol and/ororganic particulate containment therein.

In other instances, it is desirable to direct to air gas stream intoequipment. When such is the case, it may desirable to separateaerosolized liquids and/or particulates from the stream duringcirculation, in order to provide such benefits as: reduced negativeeffects on the downstream equipment; improved efficiency; recapture ofotherwise lost oil; and/or to address environmental concerns.

Improvements in crankcase ventilation filter systems (i.e. blow by gasfiltration systems) constructed for application with a variety of engineor equipment systems, are generally sought.

SUMMARY OF THE DISCLOSURE

Crankcase ventilation filter arrangement is described, as well ascomponents therefor. The crankcase ventilation filter arrangementincludes a housing and serviceable filter cartridge. An example housingincludes a cover assembly and a base (in an example a bowl), which areremovably secured to another, for example with threaded arrangement. Thefilter cartridge is removably installed with an interior of the housing.In an example depicted, the filter cartridge includes a check valveassembly therein, for protection during vehicle rollover.

Other advantageous features of the filter cartridge are described.Examples include a handle arrangement mounted on one end of the filtercartridge, as well as structural detail to ensure proper fitting of thecartridge within the assembly. Also, methods of assembly are described.

It is noted that there is no requirement that an assembly or componentinclude all of the features described herein, to obtain some advantageaccording to the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic side elevational view of the crankcase ventilationfiltration assembly according to the present disclosure.

FIG. 2 is a schematic bottom plan view of the assembly depicted in FIG.1.

FIG. 3 is a schematic cross-sectional view taken generally along line3-3 FIG. 1.

FIG. 4 is a schematic, exploded, perspective view of the assemblydepicted in FIGS. 1-3.

FIG. 5 is a schematic, side elevational view of a cartridge componentusable in the assembly of FIGS. 1-4.

FIG. 6 is a schematic, cross-sectional view of the cartridge componentof FIG. 5; FIG. 6 being taken along line 6-6, FIG. 7

FIG. 7 is top plan view of the cartridge component depicted in FIGS. 5and 6.

FIG. 8 is a schematic exploded perspective view of the cartridgecomponent depicted in FIGS. 5-7.

FIG. 9 is a perspective view of a core component usable in the cartridgecomponent of FIGS. 5-8.

FIG. 10 is schematic, first, side elevational view of the core componentdepicted in FIG. 9.

FIG. 11 is a schematic top plan view of the core component depicted inFIG. 10.

FIG. 12 is schematic bottom view of the core component depicted in FIG.10.

FIG. 13 is a schematic, cross-sectional, view of the component depictedin FIG. 10; FIG. 13 being taken along line 13-13, FIG. 10.

FIG. 14 is a second, schematic, cross-sectional of the componentdepicted in FIG. 10; FIG. 14 being taken along line 14-14, FIG. 11.

FIG. 15 is perspective view of a check valve end member of the cartridgedepicted in FIGS. 5-8.

FIG. 16 is a side elevational view of the end member of FIG. 15.

FIG. 17 is a schematic, cross-sectional view of the side piece componentdepicted in FIG. 16; the view of FIG. 17 being taken along line 17-17FIG. 18.

FIG. 18 is schematic top plan view of the component depicted in FIG. 16.

FIG. 19 is a schematic view of an equipment system including a filterassembly according to the present disclosure therein.

FIG. 20 is a schematic side elevational view of alternate filtercartridge including features according to the present disclosure.

FIG. 21 is a schematic, top plan view of the filter cartridge of FIG.20.

FIG. 22 is a schematic, cross-sectional view of the filter cartridge ofFIG. 20; FIG. 22 being taken along line 22-22, FIG. 20.

FIG. 23 is a schematic, exploded, perspective view of the filtercartridge of FIG. 20.

FIG. 24 is a schematic, fragmentary, side elevational view of a filtercartridge in accord with FIG. 20, depicted in association with housingcomponentry.

FIG. 25 is a schematic, cross-sectional view of the assembly of FIG. 24.

FIG. 26 is a schematic, partially exploded, perspective view of thefeatures of FIG. 24.

FIG. 27 is a schematic, cross-sectional view of a housing top portion,of the assembly of FIG. 24.

FIG. 28 is a schematic, exploded perspective view of the housing topcomponent of FIG. 27.

FIG. 29 is a schematic, perspective view of a cartridge component of thecartridge of FIG. 20.

FIG. 30 is a schematic side elevational view of the cartridge componentof FIG. 29.

FIG. 31 is a schematic side elevational view of the cartridge componentof FIG. 29.

DETAILED DESCRIPTION I. Crankcase Ventilation (CCV) Filter AssemblyFeatures A. General Features of the Assembly

The reference numeral 1, FIG. 1, generally represents a crankcaseventilation filter assembly according to the present disclosure. Theassembly 1, depicted in FIG. 1, includes a housing 2 defining a housinginterior and including a housing base 3, a top cover or cover assembly 4and an internally received, serviceable, i.e. removable and replaceable,filter cartridge service component, not depicted in FIG. 1 but shown inFIG. 5 at reference numeral 5.

In general, the housing 2 includes a gas flow inlet tube 10, a liquiddrain outlet 11, and a gas flow outlet tube 12. For the example assembly1 depicted in FIG. 1, the gas flow inlet tube 10 and the gas flow outlettube 12 are positioned in the cover assembly 4; and, liquid drain outlet11 is positioned in the housing base 3.

Referring to FIG. 1, it is noted for the example system, the gas flowinlet tube 10 and the gas flow outlet tube 12 are located at the samevertical height within the assembly 1. That is, line 13 is a center linefor each of the gas flow inlet tube 10 and gas flow outlet tube 12, line13 being generally perpendicular to a center vertical line 14 for theoverall assembly 1 (when installed).

In use, blow by gases (crankcase ventilation gases) are directed intothe assembly 1 through inlet tube 10, as shown at arrow 10 a. Within theassembly 1, at least of portion of liquid particles (droplets) carriedwithin the crankcase ventilation gases coalesce, and drain outwardlyfrom the assembly 1 through the drain outlet 11, typically at leastunder gravity influence. The gases are filtered, and the outlet gasesleave the assembly 1 through gas flow outlet tube 12, as shown at arrow12 a.

The base 3 is removable from the cover assembly 4. Referring to FIG. 3,the base 3 is provided with an open upper end 3 u having threads (in theexample, internal threads) 15 thereon. The cover assembly 4 includes adownwardly projecting flange 16 with threads (in the example shown,outer threads) 17 thereon. The bowl or base 3 is removably secured tothe cover assembly 4 by threaded engagement between threads 3 u on thebase 3, and threads 17 on the cover assembly 4.

After a period of use, the internally cartridge received 5 willtypically need to be serviced, for example by refurbishment orreplacement. When such as the case: the base or bowl 3 is separated fromthe cover assembly 4; the cartridge 5 is removed from the assembly 1;and, a new or refurbished cartridge 5 is installed. Herein, a cartridge5 which is removable and replaceable within the housing 2 is generallyreferred as a “serviceable” cartridge or by similar terms.

Referring to FIG. 3, when crankcase ventilation gases enter the assembly1 via inlet tube 10 (FIG. 1) the gases are first directed into interiorgas receiver region 20. From here, the gases are directed into annulus22 surrounding cartridge 5. The gases are then passed through media 25into cartridge open interior 26. The gases then pass from cartridge openinterior 26 upwardly into volume 30 within cover assembly 4, surroundedby flange 95. The gases then pass into interior region 31 of outlet tube12 and outwardly from assembly 1, FIG. 1. It is noted that on passagefrom volume 30 into interior region 31 of outlet tube 12, the gas flowis regulated by regulator arrangement 35 comprising diaphragm 36 and abiasing member 37. In this instance the biasing member 37 is shown as acoiled spring 38 nested within interior region 31 (of outlet flow tube12) and against diaphragm 36.

In more general terms, outlet tube 12 includes an outer region 12 x,FIG. 1 and an inner region 31, FIG. 3. Region 31 is generally u-shapedand operates as a flow channel to help direct air to outer region 12 x.Herein, both sections 31 and 12 x are referred to, together, as theoutlet tube 12.

Referring still to FIG. 3, the assembly 1 includes a pressure reliefvalve assembly 40 thereon. The pressure release valve assembly 40, forthe example shown, is configured to provide relief of pressure fromwithin region 20, by venting to the atmosphere in the case of thepressure spike within assembly 1. This will provide for protection ofengine gaskets and other equipment in the presence of pressure spikeswithin the system. The pressure relief valve assembly 40 comprises arelief valve member 41 biased closed under coiled spring 42, until anopening pressure is achieved, at which point valve member 41 will biasthe direction of arrow 44, FIG. 3, opening valve opening 45 to releasepressure there from.

Still referring to FIG. 3, the cover assembly 4 includes a top 50positioned on frame piece 51. During assembly of cover assembly 4,before the top 50 is put in place, spring 38 and diaphragm 36 can beappropriately positioned. Then, when top 50 is positioned, the diaphragm36 will be securely held in position, under an appropriate biasingpressure of spring 38

Still referring to FIG. 3, member 60 is shown to be secured on coverassembly 4. Member 60 is part of an electronic differential pressuresensor. It is positioned to measure pressure drop across the filtercartridge 5. It can be connected to equipment which is remote, (notshown), for measuring and reporting pressure differential. Member 60,then, can be used to determine when filter cartridge 5 needs to bereplaced.

Attention is now directed to FIG. 2, a top plan view of assembly 1. InFIG. 2, mounting pad arrangement 65 can be seen positioned coverassembly 4 for securing the assembly 1 in place on equipment. Since thecover assembly 4 is secured by the mounting pad arrangement 65, it willbe understood that during normal servicing the bowl or base 3 will bethreaded off (or onto) cover assembly 4; cover assembly 4 generallyremaining secured in place.

Attention is now directed to FIG. 4, a perspective, partially exploded,view of assembly 1. Here, cover assembly 4 is viewable, with portion ofpressure relief valve assembly 4 depicted in exploded view. Cartridge 5can be seen. Seal member 68 will generally form a seal between bowl orbase 3 and cover assembly 4, during assembly. In FIG. 3, seal ring 68 isdepicted in cross-section, at a location where base 3 engages a bottomend of flange 16.

Referring again to FIG. 3, it is noted that cartridge 5 includes on abottom thereof, downwardly projecting members 69 to engage upwardlyprojecting members 69 x in bottom 3 z of bowl 3. These can be used tohelp secure the cartridge 5 in place.

It is noted that in a typical use, a drain tube will be attached tooutlet 11. The drain tube can be provided with a valve therein, toensure the liquid won't flow back from the line into the assembly 1.

B. Cartridge Features

Attention is now directed to FIGS. 5 and 6, in which cartridge 5 isdepicted separately from assembly 1. Referring first to FIG. 5,cartridge 5 comprises media pack 25. The media pack 25 is depictedpositioned between first and second end pieces 70, 71. Second (lower)end piece 71 will generally be positioned directed downwardly in use.The second end piece 71 includes a central, axially projecting(downward), projection 72 thereon, around which seal member 73, in thisinstance comprising o-ring 74, is positioned. The term “axiallyprojecting” in this context, when used in reference to projection 72,generally means projection 72 extends in a direction opposite end piece70. When cartridge 5 is installed in the base 3, FIG. 3, seal member 73is sealed to flange 3 f, positioned as a bottom flange in base 3,adjacent to bottom 3 b of the base 3. For the particular example shown,the o-ring 74 is positioned to provide an outwardly directed seal inengagement with flange 3 f; flange 35 forming an annular flange aroundprojection or seal support 72; in a bottom 3 z of bowl 3.

Referring to FIG. 3, it is noted that flange 72, which supports o-ring74, is spaced inwardly from outer peripheral rim 71 x and end piece 71and to support o-ring 74 (seal member 73 is inwardly from outerperipheral rim 71 x). The projection 72, for the example shown, isspaced at least 20%, usually at 30% from across media pack 25 and outeredge 25 x toward inner edge 25 i and from inner edge 25 i to outer edge25 x. This would be the typical location for support 72.

Still referring to FIG. 3 seal 73, in the form of o-ring 74, isolatesannular region 22, from a liquid receiving region 80 adjacent outlet 11.

Referring again to FIG. 5, first (upper) end piece 70 will generallyform a top end when cartridge 5 is positioned for use. First end piece70 generally includes end ring 85 and axially projecting support 86. Theterm “axially projecting” in this context, when referred to support 86,generally means projection 86 extends from ring 85 in direction oppositeend piece 71. Support 86 can be formed integral (along with ring 85)with a remainder of end piece 70 and typically will be. Support 86includes a base section 88 positioned as a seal support, for seal member89 (in the form of o-ring 90), extending there around. Referring to FIG.3, when cartridge 5 is installed for use, seal member 89, i.e., o-ring90, will engage central flange 95 in cover assembly 4, to form a sealtherewith. In general, the seal is an outwardly directed radial seal,with flange 95 surrounding support 88.

Referring to FIG. 3, it is noted that support 86 or seal member 89 ispositioned spaced from an outer peripheral 71 x inwardly. Indeedreferring to FIG. 3, support 86 position is spaced from outer edge 25 xmedia pack 25 toward inner edge 25 i. Typically, support 86 will bepositioned at least 20% usually at least 30% of the distance acrossmedia pack 25 between edges 25 x and 25 i, from outer edge 25 x and alsofrom inner edge 25 i, usually. Typically, flanges 72 and 86 will bepositioned the same distance inwardly from edge 25 x, althoughalternatives are possible.

Also typically, support 86 is positioned at least 20% across end piece71 from an outer periphery 71 x to a central aperture therethrough, fromeach of the central aperture and the outer periphery 71 x.

In general, flange 95 and seal 89, separate inlet region 20 (in coverassembly 4), from filtered gas outlet region 30, thus requiring gas flowfrom inlet tube 10 to pass through media 25 of cartridge 5, before itcan pass outwardly from outlet tube 12.

Referring again to FIG. 5, extending (projecting) axially from base sealsupport region 88, projection 86 includes framework 100 comprising anupper rail 101 and a support arrangement comprising spaced supports 102.The spaced supports 102 support rail 101 in extension spaced from base88. The spaced supports 102 provide for airflow apertures 105therebetween.

Referring to FIG. 3, air flow apertures 105 provide for flow of gasesfrom region 26 within cartridge 5, through filtered gas region 30, intotube 31. In addition, rail 101 and apertures 105 provide for convenienthandle arrangement 106 for handling cartridge 5 and positioning itwithin (or removing it from) bowl or base 3.

Referring to FIG. 3, it is noted that support 102 and upper rim 101 aregenerally positioned, on end cap 71, at a location spaced inwardly fromouter edge 25 x with the media pack 25, or toward inner edge 25 i.Typically, rail 101 and supports 102 are positioned at least 20% acrossthe media pack from edge 25 x to edge 25 i, usually at least 30%. Thisensures that the rail 101 and supports 102, i.e. resulting handlearrangement 106 is surrounded by flange 95 during assembly, and ispositioned within region 30, as intended.

Attention is now directed to FIG. 6. Referring to FIG. 6, for theexample shown cartridge 5 comprises media pack 25 and support member120. The support member 120 comprises central support 121 around whichthe media pack 25 extends. The central support 121 defines interiorregion 26. The support member 120 further includes end piece 71 withsupport 72 thereon. Further, it includes end piece 70 with ring 85 andprojection 86 (comprising seal 88 and frame piece 100 thereon). In FIG.6, o-rings 74, 90 are shown in place.

Referring to FIG. 6, one can understand that support 120, comprising endpiece 70, end piece 71 and central support 121, can comprise a single,molded, integral piece. This will be typical, although alternatives arepossible.

Referring to FIG. 6, it can be seen that end cap 70 includes a centralaperture 75 therein; and, second end cap 71 includes a central aperture71 y therethrough. Further projections 69, surrounded by support 72, canbe seen projecting from end piece 71 in a direction away from media pack25. During installation, FIG. 3, these projections can engage uprightprojections 69 x and bowl 3.

Sill referring to FIG. 6, cartridge 5 includes a check valve assembly130. The check valve assembly 130 includes a check valve member 131,second valve seat 132, valve cage 133 and end member 134. End member 134includes first valve seat 135 thereon.

During normal operation, the valve member 131 is seated against secondvalve seat 132 as shown. It can also be understood from furtherdescription below, that when valve member 131 is seated against secondvalve seat 132, no seal or closure at region 132 a is formed. Thus,liquid within interior region 26 can drain downwardly through aperture71 y into region 80, FIG. 3. In an instance of vehicle rollover,however, the valve member 131 will roll through cage 133 to seat againstsecond seat 135. When valve member 131 is seated against seat 135, seat135 is closed to liquid flow. This will inhibit undesirable liquiddrainage into an engine crankcase.

It is not required that a complete seal at seat 135 be formed to obtainsome benefit. The end member 134 is snap fit in place, to keep valvemember 131 in position. The valve member will typically comprise ahollow spherical (ball) member, as shown, although alternatives arepossible.

Still referring to FIG. 6, it can be understood that valve cage 133generally comprises support region or tube 121 of support member 120.Further, the first valve seat 132 comprises a portion of aperture 71 yin end piece 71. Region 121 provides a track, for movement, of checkvalve 131 between valve seats at opposite ends 121 x, 121 y of supportregion or tube 121.

Attention is now directed to FIG. 8, an exploded, perspective view ofthe cartridge 5, FIGS. 5 and 6. Referring to FIG. 8, seal members 89, 72are viewable. Also viewable is end piece 134 and valve member 131. Themedia pack 25 is viewable around support member 120.

Still referring to FIG. 8, it can be seen that end piece 70 comprisesring section 85, with outer periphery 85 x. Ring section 85 overlaps end25 a of media pack 25. Further, end piece 70 includes spaced, radiallyoutwardly directed projections 141. The projections 141, in FIG. 3, areengaged by downwardly projecting flange shoulder 96 in cover assembly 4,during assembly. This helps secure the cartridge 25 in position. Spacingbetween the projections 141, allows for gas and liquid flow from region20 in to annulus 22, FIG. 3.

Still referring to FIG. 3, it is noted that projections 141 also ensurethat the cartridge 5 cannot be inserted upside down, within bowl 3. Thatis, the cartridge 5 can only be inserted in one orientation, since theprojections 141 would otherwise interfere with shoulder 149.

Referring again to FIG. 8, it can be seen that upper rail 101 is notcompletely circular, but rather has a c-shape with a single gap 101 xbetween supports 102 a, 102 b. Gap 101 x is sized and shaped for innerportion 31, FIG. 3, of outlet tube 12 to be received therein and toproject therethrough, during assembly. Typically, region 101 x is anopening or gap in rail 101 which extends over a radial extension (arc)of at least 20°, typically at least 30°, usually an amount within therange of, 30° to 60° inclusive, often not more than 60°.

Still referring to FIG. 8, it can be seen for the particular projection86 depicted, rail 101 is supported by four supports 102 a-d. Analternate number of supports 102 is possible. It can be also seen byreferring to FIG. 8, that rail 101 will operate as a convenient handlemember for managing cartridge 5.

Attention is now directed to FIGS. 9-14, in which support member 120 isviewable, in a variety of views, separated from media pack 25. Referringto FIG. 9, a top perspective view is depicted showing end pieces 70, 71.End piece 70 is viewable with ring region 85 having outward projections141 thereon. Further, axial projection 86, with base 88 is viewable, aswell upper rail 101 supported by supports 102. Further, gap 101 x isviewable, as well as flow windows 105.

Also referring to FIG. 9, in end piece 71, drain aperture arrangementcomprising individual, spaced, apertures 143 can be seen extendingthrough the end piece 71. The drain aperture arrangement 143 will beoverlapped by an end of media 25, in cartridge 5, FIG. 5. The drainaperture arrangement 143 allows for liquid drainage directly downwardlyfrom the media pack, through the end piece 71, in operation. It is notedthat the drain aperture arrangement 143 is positioned with a portionadjacent to central support 121, in particular adjacent impermeable endsection 121 x of support 121.

Still referring to FIG. 9, drain apertures of drain aperture arrangement143 are generally positioned such that each is completely containedwithin a region of end cap 71 and each is positioned across end cap 71from outer circumference 71 x toward tube 121 such that apertures 143are at least 20%, usually at least 30%, and often more than 40%(typically more than 50%) across end piece 71 from periphery 71 x toaperture 71 y; i.e. at least 20% usually at least 30% often, and atleast 40% (typically more than 50%) from outer edge 25 x to inner edge25 i.

In FIG. 10, a side elevational view of support 120 taken directed towardto gap 101 x is viewable. In FIG. 11, a top, plan view of support 120 isdepicted. Here projections 145 are viewable. Projections 145 provide fororientation of a snap fit piece, discussed below in connection withFIGS. 15-18.

Referring to FIG. 11, attention is directed to spaced projections 143,within interior 26. Spaced projections 146 are positioned adjacentopposite end piece 71, see FIG. 3. Spaced projections 146 ensure thatwhen valve member 131 is positioned on end piece 71, flow spaces aroundthe valve member 131 are provided.

In FIG. 12, a bottom plan view of member 120 is viewable. Hereprojections 146 are also viewable. In FIG. 13, a cross-sectional viewtaken along line 13-13, FIG. 10 is viewable, and projections 146 arefurther defined.

In FIG. 14, a cross-sectional view along line 14-14, FIG. 12 isprovided, allowing further inspection of the described features.

Attention is now directed to FIGS. 15-18 in which various views of endmember 134 are provided. In FIG. 15, a perspective view is shown of endpiece 134. Snap fit projections 150 are viewable. These will engagesupport 120, when end piece 134 is positioned in place. In FIG. 16, aside elevational view is shown. In FIG. 17 a cross-sectional isviewable. In FIG. 18, a top plan view of end piece 134 is viewable. Itis noted that end piece 134 has a petal arrangement comprising aplurality of radially outwardly projecting, radially spaced, projections160. The projections include two projections 170, 171, distorted inshape to accommodate engagement along projections along 145, FIG. 11.

Referring still to FIG. 18, and more specifically, two projections 170,171 are truncated along edges 170 x, 171 x, along line 180. This isneeded, for engagement against projections 145 in the support member120. As a result, snap fit member 134 can only be oriented relative tosupport member 120, in one radial orientation for snap fit. This ensuresthe snap projections 150 will be aligned with receiver portions ofsupport 120 to which they can engage, during installation.

A variety of materials can be utilized for the components of assembly 1.Typically molded components will comprise glass filled polyamide,although alternatives are possible. According to FIG. 3, it is notedthat gasket 68 is received within a receiver 68 x. The receiver 68 x canbe provided with a gap therein, to facilitate replacement of gasket 68.

It is noted that under a vehicle rollover condition, in which the valvemember 131 seats against seat 135, pressure within the assembly 1 will,increase, and pressure relieve assembly 40 will open.

C. Dimensions of an Example System

In FIGS. 1-18, dimension and angle lines are provide for an examplesystem. Dimensions for the example system indicated are as follows: InFIG. 1, AA=180 mm; In FIG. 2 BA=120 mm; In FIG. 6 DA=183 mm; CB=140 mm;In FIG. 7, DA=109 mm diameter; DB=95.5 mm diameter; and, DC=92 mmdiameter; In FIG. 10, EA=28 mm; EB=6 mm; EC=3 mm; and, ED=6 mm; In FIG.11 FA=95.5 mm diameter; FB=26 mm diameter; FC=59.3 mm diameter; FD=10mm; FE=5.8 mm; FF=3 mm; FG=1.5 mm; and, FH=16.5 mm; In FIG. 12 GA=34 mmdiameter; GB=3 mm; GC=109 mm diameter; GD=48 mm diameter; In FIG. 13HA=30 mm; HB=2.4 mm; HC=4.2 mm; HD=20 mm; HE=35 mm; HF=8 mm; HG=2 mm;HH=12 mm; HI=140 mm; HJ=2 mm; HK=1 mm; HL=5 mm; HM=17 mm; HN=49 mm;HO=53 mm; HP=58.1 mm; and, HQ=8 mm; In FIG. 14, IA=3 mm; IB=0.2 mmradius; IC=1 mm radius; ID=26 mm; IE=1.5 mm; and, IF=29.9 mm; In FIG.16, JA=10.5 mm; JB=4.5 mm; and, JC=54′; In FIG. 17, KA=22 mm; KB=26.6°;KC=2 mm; KD=17.5 mm; KE=0.5 mm radius; KF=3 mm radius; KG=18 mm; KH=23mm; KI=25.6 mm; and, KJ=28.8; and, In FIG. 18, LA=3 mm radius; LB=26 mmdiameter; LC=2 mm radius; LD=5.6 mm; and, LE=20°.

D. An Example System, FIG. 19

Attention is directed to FIG. 19, which shows an example system andincluding a filter assembly 1 according to the present. Referring toFIG. 19, the system 250 includes an engine 251. The filter assembly 1 isdepicted, schematically, orientated to receive crankcase ventilationflow from the engine 251. At 252 off gases from the filter assembly areshown directed ultimately to inlet 253 of turbo 254. In FIG. 19, airclearer arrangement 260 is shown, which provides for filtered andambient air flow to the turbo 254 and the engine 251.

Of course, the off gases 252 can be directed elsewhere, for example intoair cleaner 260, if desired.

In general, the system 250 depicted is “closed” in that filtered offgases from the filter arrangement 1 are not vented directed to theatmosphere, but rather are cycled back into the engine intake, indicatedgenerally at 270.

II. Usable Media A. General Characteristics

The appropriate media, for the media pack, is selected for theconditions of use. Generally the media is selected to have appropriateproperties with respect to: coalescing and drainage of liquid; and,filtering of gases passing therethrough with respect to particulates.Layers of media can be utilized for the media of the media pack. Exampleusable media is described in U.S. Provisional Application Ser. No.60/731,287, filed Oct. 28, 2005, PCT Application PCT/US2006/041738,filed Oct. 27, 2006, U.S. Provisional Application 60/656,806, filed Feb.22, 2006; and, PCT Publication WO06/91594, published Aug. 31, 2006, andPCT Publication WO 2006/084282, published Oct. 19, 2006, each of whichis incorporated herein by reference.

Typically the media will comprise a continuous, non-woven, fibrousmedia.

An example useable media as described in U.S. provisional application60/656,806 filed Feb. 22, 2005, incorporated herein by reference.Another example media is described in PCT Publication WO 05/083,240,published Sep. 9, 2005, and incorporated herein by reference. A thirdexample media is described in U.S. provisional application 60/650,051filed Feb. 4, 2005, incorporated herein by reference. The followingdescription is of example media from U.S. provisional application60/650,051, filed Feb. 4, 2005.

The media is typically a wet laid media is formed in a sheet form usingwet laid processing, and is then positioned on/in the filter cartridge.Typically the wet laid media sheet is at least used as a media stagestacked in multiple layers.

As indicated, multiple layers, forming a gradient can be provided in amedia stage, by first applying one or marc layers of wet laid media offirst type and then applying one or marc layers of a media (typically awet laid media) of a different, second, type. Typically when a gradientis provided, the gradient involves use of two or marc media types whichare selected for at least differences in efficiency.

Herein, it is important to distinguish between the definition of themedia sheet used to form the media stage, and the definitions of theoverall media stage itself. Herein the term “wet laid sheet,” “mediasheet” or variants thereof, is used to refer to the sheet material thatis used to form the media extension of a filter, as opposed to theoverall definition of the total media extension in the filter. This willbe apparent from certain of the following descriptions.

Media extensions of the type of primary concern herein, are at leastused for coalescing/drainage, although they typically also haveparticulate removal function and thus comprise a portion of an overallmedia stage that provides for both coalescing/drainage and desiredremoval efficiency of solid particulate removal.

Although alternatives are possible, an example media composition used toform a media extension in a CCV (crankcase ventilation) filter forcoalescing/drainage is typically as follows:

-   -   1. Although alternatives are possible for different        applications, it is typically provided in a form having a        calculated pore size (X-Y direction) of at least 10 micron,        usually at least 12 micron. The pore size is typically no        greater than 60 micron, for example within the range of 12-50        micron, typically 15-45 micron.    -   2. It is typically formulated to have a DOPE % efficiency (at        10.5 fpm for 0.3 micron particles), within the range of 3-18%,        typically 5-15%.    -   3. It typically comprises at least 30% by weight, typically at        least 40% by weight, often at least 45% by weight and usually        within the range of 45-70% by weight, based on total weight of        filter material within the sheet, bi-component (binder) fiber        material in accord with the general description provided herein.    -   4. It typically comprises 30 to 70% (typically 30-55%), by        weight, based on total weight of fiber material within the        sheet, of secondary fiber material having average largest        cross-sectional dimensions (average diameter if round) of at        least 1 micron, for example within the range of 1 to 20 micron.        In some instances it will be 8-15 micron. The average lengths        are typically 1 to 20 mm, often 1-10 mm. This secondary fiber        material can be a mix of fibers. Typically polyester and/or        glass fibers are used, although alternatives are possible.    -   5. Typically and preferably the fiber sheet (and resulting media        extension) includes no added binder other than the binder        material contained within the bi-component fibers. If an added        resin or binder is present, preferably it is present at no marc        than about 7% by weight of the total fiber weight, and marc        preferably no marc than 3% by weight of the total fiber weight.

Media in accord with the general definitions provided herein, includinga mix of bi-component (binder) fiber and other fiber, can be used as any(and in some instances all) layer(s) of a media stage in a crankcaseventilation filter as generally described above. When used in thismanner, it will typically be placed in multiple layers, althoughalternatives are possible. The overall efficiency can be calculatedbased upon the number of layers and the efficiency of each layer. Forexample the efficiency at 10.5 feet per minute (3.2 m/min) for 0.3micron DOPE particles for media stage comprising two layers of wet laidmedia each having an efficiency of 12% would be 22.6%, i.e.,12%+0.12×88.

Typically enough media sheets would be used in the final media stage toprovide the media stage with overall efficiency of at least 85%,typically 90% or greater. In some instances it would be preferred tohave the efficiency at 95% or marc. In the context the term “final mediastage” refers to a stage resulting from wraps or coils of the sheet(s)of the media.

B. The Preferred Calculated Pore Size

The media extension performs two important functions:

-   -   1. It provides for some coalescing and drainage of oil particles        carried in the crankcase ventilation gases being filtered; and    -   2. It provides for selected filtration of other particulates in        the gas stream.

In general, if the pore size is too low:

-   -   a. Drainage of coalesced oil particles by gravity, downwardly        through (and from) the media, can be difficult or slowed, which        leads to an increase of re-entrainment of the oil into the gas        stream; and    -   b. Unacceptable levels of restriction are provided to the        crankcase gas flow through the media.

In general, if the porosity is too high:

-   -   a. Oil particles are less likely to collect and coalesce; and    -   b. A large number of layers, and thus media thickness, will be        necessary to achieve an acceptable overall level of efficiency        for the media pack.

It has been found that for crankcase ventilation filters, a calculatedpore size for media used to form media extension within the range of 12to 50 micron is generally useful. Typically the pore size is within therange of 15 to 45 micron.

The term X-Y pore size and variants thereof when used herein, is meantto refer to the theoretical distance between fibers in a filtrationmedia. X-Y refers to the surface direction versus the Z direction whichis the media thickness. The calculation assumes that all the fibers inthe media are lined parallel to the surface of the media, equallyspaced, and ordered as a square when viewed in cross-sectionperpendicular to the length of the fibers. The X-Y pore size is adistance between the fiber surfaces on the opposite corners of thesquare. If the media is composed of fibers of various diameters, the d²mean of the fiber is used as the diameter. The d² mean is the squareroot of the average of the diameters squared.

It has been found, in some instances, that it is useful to havecalculated pore sizes on the higher end of the preferred range,typically 30 to 50 micron, when the media stage at issue has a totalvertical height, in the crankcase ventilation filter of less than 7inches (178 mm); and, pore sizes on the smaller end, about 15 to 30micron, are sometimes useful when the filter cartridge has a height onthe larger end, typically 7-12 inches (178-305 mm). A reason for this isthat taller filter stages provide for a higher liquid head, duringcoalescing, which can force coalesced liquid flow, under gravity,downwardly through smaller pores, during drainage. The smaller pores, ofcourse, allow for higher efficiency and fewer layers.

Of course in a typical operation in which the same media stage is beingconstructed for use in a variety of filter sizes, typically for at leasta portion of the wet laid media used for the coalescing/drainage ininitial separation, an average pore size of about 30-50 microns will beuseful.

C. Solidity

Solidity is the volume fraction of media occupied by the fibers. It isthe ratio of the fibers volume per unit mass divided by the media'svolume per unit mass.

Typical materials preferred for use in media extension according to thepresent disclosure, have a percent solidity at 0.125 psi (8.6 milliards)of fewer than 10%, and typically fewer than 8%, for example 6-7%.

D. Preferred DOPE Efficiency at 10.5 Ft/Minute for 0.3 Micron Particles

The preferred efficiency stated, is desirable for layers or sheets ofmedia to be used to generate crankcase ventilation filters. Thisrequirement indicates that a number of layers of the wet laid media willtypically be required, in order to generate an overall desirableefficiency for the media stage of typically at least 85% or often 90% orgreater, in some instances 95% or greater.

The reason a relatively low efficiency is provided in any given layer,is that it facilitates coalescing and drainage and overall function.

In general, DOPE efficiency is a fractional efficiency of a 0.3 micronDOPE particle (dactyl phthalate) challenging the media at 10 fpm. A TSARmodel 3160 Bench (TSAR Incorporated, St. Paul, Minn.) can be used toevaluate this property. Model dispersed particles of DOPE are sized andneutralized prior to challenging the media.

III. The Media Composition A. The Bi-Component Fiber Constituent

As indicated above, it is preferred that the fiber composition of themedia include 30 to 70%, by weight, of bi-component (binder) fibermaterial. A major advantage of using bi-component fibers in the media,is effective utilization of fiber size while maintaining a relativelylow solidity. With the bi-component fibers, this can be achieved whilestill accomplishing a sufficiently high strength media for handlinginstallation in crankcase ventilation filters. Also, the bi-componentfibers are binder fibers.

The bi-component fibers generally comprise two polymeric componentsformed together, as the fiber. Various combinations of polymers for thebi-component fiber may be useful, but it is important that the firstpolymer component melt at a temperature lower than the meltingtemperature of the second polymer component and typically below 205° C.Further, the bi-component fibers are integrally mixed and evenlydispersed with the other fibers, in forming the wet laid media. Meltingof the first polymer component of the bi-component fiber is necessary toallow the bi-component fibers to form a tacky skeletal structure, whichupon cooling, captures and binds many of the other fibers, as well asother bi-component fibers.

Although alternatives are possible, typically the bi-component fiberswill be formed in a sheath core form, with a sheath comprising the lowermelting point polymer and the core forming the higher melting point.

In the sheath-core structure, the low melting point (e.g., about 80 to205° C.) thermoplastic is typically extruded around a fiber of thehigher melting point material (e.g., about 120 to 260° C.). In use, thebi-component fibers typically have a average largest cross-sectionaldimension (average fiber diameter if round) of about 5 to 50 micrometeroften about 10 to 20 micrometer and typically in a fiber form generallyhave an average length of at least 1 mm, and not greater than 30 mm,usually no marc than 20 mm, typically 1-10 mm. By “largest” in thiscontext, reference is meant to the thickest cross-section dimension ofthe fibers.

Such fibers can be made from a variety of thermoplastic materialsincluding polyolefin's (such as polyethylene's, polypropylenes),polyesters (such as polyethylene terephthalate, polybutyleneterephthalate, PCT), nylons including nylon 6, nylon 6, 6, nylon 6, 12,etc. Any thermoplastic that can have an appropriate melting point can beused in the low melting component of the bi-component fiber while highermelting polymers can be used in the higher melting “core” portion of thefiber. The cross-sectional structure of such fibers can be a“side-by-side” or “sheath-core” structure or other structures thatprovide the same thermal bonding function. One could also use lobedfibers where the tips have lower melting point polymer. The value of thebi-component fiber is that the relatively low molecular weight resin canmelt under sheet, media, or filter forming conditions to act to bind thebi-component fiber, and other fibers present in the sheet, media, orfilter making material into a mechanically stable sheet, media, orfilter.

Typically, the polymers of the bi-component (core/shell or sheath andside-by-side) fibers are made up of different thermoplastic materials,such as for example, polyolefin/polyester (sheath/core) bi-componentfibers whereby the polyolefin, e.g. polyethylene sheath, melts at atemperature lower than the core, e.g. polyester. Typical thermoplasticpolymers include polyolefins, e.g. polyethylene, polypropylene,polybutylene, and copolymers thereof, polytetrafluoroethylene,polyesters, e.g. polyethylene terephthalate, polyvinyl acetate,polyvinyl chloride acetate, polyvinyl butyral, acrylic resins, e.g.polyacrylate, and polymethylacrylate, polymethylmethacrylate,polyamides, namely nylon, polyvinyl chloride, polyvinylidene chloride,polystyrene, polyvinyl alcohol, polyurethanes, cellulosic resins, namelycellulosic nitrate, cellulosic acetate, cellulosic acetate butyrate,ethyl cellulose, etc., copolymers of any of the above materials, e.g.ethylene-vinyl acetate copolymers, ethylene-acrylic acid copolymers,styrene-butadiene block copolymers, Kraton rubbers and the like.Particularly preferred in the present invention is a bi-component fiberknown as 271P available from DuPont. Others fibers include FIT 201,Kuraray N720 and the Nichimen 4080 and similar materials. All of thesedemonstrate the characteristics of cross-linking the sheath polymer uponcompletion of first melt. This is important for liquid applicationswhere the application temperature is typically above the sheath melttemperature. If the sheath does not fully crystallize then the sheathpolymer will remelt in application and coat or damage downstreamequipment and components.

An example of a useable bi-component (binder) fiber for forming wet laidmedia sheets for use in CCV media is DuPont polyester bi-component 271P,typically cut to a length of about 6 mm.

B. The Secondary Fiber Materials

The bi-component fibers provide a matrix for the crankcase ventilationfilter media. The additional fibers or secondary fibers, sufficientlyfill the matrix to provide the desirable properties for coalescing andefficiency.

The secondary fibers can be polymeric fibers, glass fibers, metalfibers, ceramic fibers or a mixture of any of these. Typically glassfibers, polymeric fibers or a mixture are used.

Glass fibers useable in filter media of the present invention includeglass types known by the designations: A, C, D, E, Zero Boron E, ECR,AR, R, S, S-2, N, and the like, and generally, any glass that can bemade into fibers either by drawing processes used for makingreinforcement fibers or spinning processes used for making thermalinsulation fibers.

Non-woven media of the invention can contain secondary fibers made froma number of both hydrophilic, hydrophobic, oleophilic, and oleophobicfibers. These fibers cooperate with the glass fiber and the bi-componentfiber to form a mechanically stable, but strong, permeable filtrationmedia that can withstand the mechanical stress of the passage of fluidmaterials and can maintain the loading of particulate during use.Secondary fibers are typically monocomponent fibers with average largestcross-sectional dimension (diameters if round) that can range from about0.1 on up, typically 1 micron or greater, often 8-15 microns and can bemade from a variety of materials including naturally occurring cotton,linen, wool, various cellulosic and proteinaceous natural fibers,synthetic fibers including rayon, acrylic, aramide, nylon, polyolefin,polyester fibers. One type of secondary fiber is a binder fiber thatcooperates with other components to bind the materials into a sheet.Another type of secondary fiber is a structural fiber that cooperateswith other components to increase the tensile and burst strength thematerials in dry and wet conditions. Additionally, the binder fiber caninclude fibers made from such polymers as polyvinyl chloride, polyvinylalcohol. Secondary fibers can also include inorganic fibers such ascarbon/graphite fiber, metal fiber, ceramic fiber and combinationsthereof.

The secondary thermoplastic fibers include, but are not limited to,polyester fibers, polyamide fibers, polypropylene fibers,copolyetherester fibers, polyethylene terephthalate fibers, polybutyleneterephthalate fibers, polyetherketoneketone (PEKK) fibers,polyetheretherketone (PEEK) fibers, liquid crystalline polymer (LCP)fibers, and mixtures thereof. Polyamide fibers include, but are notlimited to, nylon 6, 66, 11, 12, 612, and high temperature “nylons”(such as nylon 46) including cellulosic fibers, polyvinyl acetate,polyvinyl alcohol fibers (including various hydrolysis of polyvinylalcohol such as 88% hydrolyzed, 95% hydrolyzed, 98% hydrolyzed and 99.5%hydrolyzed polymers), cotton, viscose rayon, thermoplastic such aspolyester, polypropylene, polyethylene, etc., polyvinyl acetate,polylactic acid, and other common fiber types.

Mixtures of the fibers can be used, to obtain certain desiredefficiencies and other parameters.

The sheet media of the invention are typically made using papermakingprocesses. Such wet laid processes are particularly useful and many ofthe fiber components are designed for aqueous dispersion processing.However, the media of the invention can be made by air laid processesthat use similar components adapted for air laid processing. Themachines used in wet laid sheet making include hand laid sheetequipment, Fourdrinier papermaking machines, cylindrical papermakingmachines, inclined papermaking machines, combination papermakingmachines and other machines that can take a properly mixed paper, form alayer or layers of the furnish components, remove the fluid aqueouscomponents to form a wet sheet. A fiber slurry containing the materialsare typically mixed to form a relatively uniform fiber slurry. The fiberslurry is then subjected to a wet laid papermaking process. Once theslurry is formed into a wet laid sheet, the wet laid sheet can then bedried, cured or otherwise processed to form a dry permeable, but realsheet, media, or filter. For a commercial scale process, thebi-component mats of the invention are generally processed through theuse of papermaking-type machines such as commercially availableFourdrinier, wire cylinder, Stevens Former, Roto Former, Inver Former,Venti Former, and inclined Delta Former machines. Preferably, aninclined Delta Former machine is utilized. A bi-component mat of theinvention can be prepared by forming pulp and glass fiber slurries andcombining the slurries in mixing tanks, for example. The amount of waterused in the process may vary depending upon the size of the equipmentused. The furnish may be passed into a conventional head box where it isdewatered and deposited onto a moving wire screen where it is dewateredby suction or vacuum to form a non-woven bi-component web.

The binder in the bi-component fibers is activated by passing the mattthrough a heating step. The resulting material can then be collected ina large roll if desired.

C. Surface Treatments of the Fibers

Modification of the surface characters of the fibers, increase in thecontact angle, can enhance drainage capability of filtration media andthus the formed elements of the filter (with respect to pressure dropand mass efficiency). A method of modifying the surface of the fibers isto apply a surface treatment such as a flourochemical or siliconecontaining material, typically up to 5% by weight of the media.

The surface treatment agent can be applied during manufacture of thefibers, during manufacture of the media or after manufacture of themedia post-treatment, or after provision of the media pack. Numeroustreatment materials are available such as flourochemicals or siliconecontaining chemicals that increase contact angle. An example is theDuPont Zonyl™ flourochemicals, such as #7040 or #8195.

IV. An Alternate, Second, Embodiment, FIGS. 20-31

In FIGS. 20-31, features related to a crankcase ventilation filterarrangement, in an alternate form to that previously discussed above,are depicted. In general, then, these figures reflect a secondembodiment incorporating principles according to the present disclosure.

Attention is first directed to FIG. 20, in which a crankcase ventilationfilter 300 is depicted in side elevational view. The cartridge 300comprises a media pack 301 positioned between: a first, upper, end piece302; and, a second, lower, end piece 303.

An axial projection arrangement 305 is depicted projecting, axially,from end piece 303 in direction away from end piece 302 and media pack301. The projection arrangement 305 includes a seal arrangement 306thereon. The seal arrangement 306, for the example cartridge 300depicted, comprises a radial seal in the form of an o-ring 307positioned to surround a portion of projection arrangement 305.

Still referring to FIG. 20, axial projection arrangement or support 310is provided projecting axially from end piece 302 in a directionopposite media pack 301, projection arrangement 305 and end piece 303.The projection arrangement 310 includes a base 311 comprising in part aseal support 312 with a seal arrangement 313, in the example depictedcomprising a radial seal in the form of an o-ring 314.

In addition, the projection arrangement 310 includes a framework 317projecting from the base 311 generally in a direction away from mediapack 301 and end piece 303. The framework 317 comprises an upper rail320 and a support arrangement 321. It is noted that for the particularexample cartridge 300 depicted, the upper rail arrangement 320 comprisestwo spaced arcuate, rail sections 320 x, 320 y.

In FIG. 21, a top plan view of cartridge 300 is depicted. Here, endpiece 302 is viewable and can be seen to have an open central, aperture330. Two rail sections 320 x, 320 y are viewable. It is noted that eachsection, 320 x, 320 y is arcuate, and the two gaps between the railsegments 320 x, 320 y are shown generally at 332, 333. For the examplecartridge 300 depicted, the gaps 332, 333 are each, angularly, the samesize, and each is at least 20°.

Attention is now directed to FIG. 22, a cross-sectional view takengenerally along line 22-22, FIG. 20. Here media pack 301 can be seen tohave an outer perimeter or edge 301 x and an inner perimeter or edge 301i. The media pack 301 can be seen to be positioned on a central coresupport 340, which is perforated to allow gas flow therethrough.

Also, referring to FIG. 22, it can be seen for the example cartridge 300depicted, the media pack 301 is positioned around a support member 345comprising: support 340, end piece 302, end piece 303, projectionarrangement 305 and projection arrangement 310, as a single, integral,molded piece.

Still referring to FIG. 22, it is noted that seal member 306, comprisingo-ring 307, is positioned to axially overlap with the media pack 301 ata location spaced at least 20% and indeed at least 30% of a distanceacross the media pack 301 between the edges 301 x, 301 y, from each ofthe edges 301 x, 301 y.

Further, it can be seen that the seal arrangement 306 is positioned onprojection 305 spaced from end piece 303. Typically, the distance D1 ofthis spacing would be at least 14 mm, usually at least 18 mm, andtypically within the range of 18-40 mm.

Referring still to FIG. 22, it is noted that support arrangement 321 forrail 320 is configured to define apertures 349 under rail 320, for airflow and to facilitate handling.

In FIG. 23, an exploded perspective view of cartridge 300 is depicted.The various components of cartridge 300 viewable are as follows: o-ring307; support member 345; media pack 301; and, o-ring 314.

It is noted that the media pack 301 is depicted schematically in thedrawings. The media pack 301 could, for example, comprise a coiled wrapof media as characterized herein.

Cartridge 300 can be used analogously to cartridge 5, in anappropriately configured filter assembly. An example filter assembly foruse with cartridge 300, is depicted in FIGS. 24-26.

Referring first to FIG. 24, cartridge 300 is depicted positioned withina filter assembly 375. The filter assembly 375 depicted, includes ahousing 376; and internally received cartridge 300. The housing 376includes a housing base 377 (depicted in phantom) and a cover assemblyor top 378. The housing 376 further includes a liquid drain arrangement379, also depicted in phantom.

The particular housing 376 depicted, is configured to receive flow ofgases to be filtered from a bottom, as generally shown by arrows 381.Liquid drain is generally shown at arrow 382, and filtered gas (air)exit is shown at arrow 383.

Attention is now directed to FIG. 25, a cross-sectional view of assembly375. Referring to FIG. 25, cartridge 300 can be seen sealed within aninterior 376 i of housing 376. In particular, seal arrangement 306, onprojection 305 is shown sealed against interior surface 379 i of drain379. Seal arrangement 313, i.e. o-ring 314 is shown sealed against aninner flange 385 positioned within cover assembly or top 378.

Referring to FIG. 25, it can be seen that during normal filtering, thegas (air) flow is directed into media pack 301 from an exterior 301 x,to an interior 301 i. Air flow is then directed to interior 340 i oftube 340. The air flow can then move upwardly through tube 340 into top378. Regulator valve arrangement 390 is provided, to regulate flow ofgases. The gases, as regulated by the regulator valve arrangement 390,are passed into outlet arrangement 391. From here, the gases can exitthe assembly 375. It is noted that outlet 391 is configured to passthrough at least one of the gaps 332, 333, depending on the rotationalalignment of cartridge 300 within housing 376.

Assembly 375 also includes a bypass valve assembly 395, for allowingdirect gas flow from gas flow inlet to bypass cartridge 300, to reachoutlet 391.

In FIG. 26, a partially exploded view of assembly 375 is depicted. FromFIG. 26, it will be understood that top 378 can be configured and thenbe attached, as appropriate, to a housing base 377.

In FIG. 27, a cross-sectional view of top 378 is depicted. Hereregulator valve arrangement 390, comprising a diaphragm 390 x and spring390 s is viewable.

In FIG. 28, an exploded perspective view of top 378 is provided.

In FIGS. 29-31, various views of support member 345 are provided.

Referring to FIG. 29, support member 345 is viewable comprising support340, end piece 302, projection arrangement 310, end piece 303, andprojection arrangement 305. It is noted that end piece 303 includesaperture arrangement 400 therethrough, in the example comprisingindividual apertures 401 extending through end piece 303 at a locationaround, and spaced outwardly from, support 340. Analogously to apertures143, FIG. 9, aperture arrangement 400 will operate as a drain aperturearrangement, allowing for direct liquid drainage downwardly from themedia pack 301, FIG. 22. Thus liquid does not have to flow through tube340, to reach the housing lower drain 379, although some can.

In FIG. 30, a side elevational view of support 345 is depicted. In FIG.31, a cross-sectional view of support 345 is provided.

Referring to FIG. 29, it is noted that end piece 303 is not completelycircular, but rather has one straight, truncated, section 303 x.Truncated section 303 x can be configured, in engagement with a portionof a housing, to ensure that the cartridge 300 is in a single rotationalorientation, relative to the housing, when installed.

In FIGS. 20-31, some example dimensions are provided as follows: MA=206mm; NA=94 mm; OA=223.9 mm; PA=138.3 mm; QA=138.3 mm; QB=83.5 mm; RA=21.5mm; RB=5.5 mm; RC=18 mm; RD=10.9 mm; RE=15 mm; RF=12.5 mm; RG=7.2 mm;SA=45.4 mm; SB=30 mm; SC=5 mm; SD=6 mm; SE=36.5 mm; SF=2.5 mm; SG=166.7mm; SH=140 mm; SI=61 mm; SJ=7.5 mm; SL=4 mm; SM=52.3 mm; SN=56.7 mm;SO=8.5 mm; SP=60.7 mm; and, SQ=29.2 mm.

It is noted that valve arrangement, generally in accord with thatdescribed herein above in connection with previously described figures,can be adapted for use with the cartridge of FIG. 20. It is also notedthat the cartridge of FIG. 20 could be incorporated into a housinghaving features generally in accord with FIGS. 1-3, if the housing wereappropriately adapted to accommodate the bottom of the seal arrangementsof cartridge 300.

V. Some General Comments and Observations

In general terms, according to one aspect of the present disclosure, acrankcase ventilation filter assembly is provided. The assembly includesa housing defining an interior and including a bowl (or housing base)and a cover assembly. The cover assembly, in one example, includes: anair flow outlet tube, including an inner section; an airflow inlet tube;an internal flange; and, an external flange. In one example the air flowoutlet tube and the air flow inlet tube are centered on a single line,which extends generally perpendicular to a center line extending throughthe bowl and cover assembly, such center line typically being a verticalline in installation, see FIG. 3.

The bowl (or housing base) typically defines an interior and isreleasably secured to the cover assembly. The bowl (or housing base)includes a bottom with a liquid drain surrounded by an internal sealflange.

In more general terms, a crankcase ventilation filter assembly isprovided which includes a housing having: an air flow inlet; an air flowoutlet; and, a liquid drain outlet.

The assembly further includes a filter cartridge removably positionedwithin the housing interior. The filter cartridge generally comprises: amedia pack surrounding an open filter interior; first and second,opposite, end pieces at opposite ends of the filter media; and, firstand second seal members.

In an example shown and described, the first end piece includes a firstaxial projection thereon, on an opposite side of the first end piecefrom the media pack and extending away from the second end piece. Thefirst axial projection has a first seal support thereon, with a firstseal member mounted on first seal support and positioned for sealingengagement with the internal flange of the cover assembly.

In an example shown, the first axial projection includes a frameworkextending from the first seal support in a direction away from themedia. This framework includes an upper rail or rail arrangementsupported by a support arrangement, an example shown comprising spacedsupports. The upper rail or rail arrangement is positioned at a locationabove the lower most portion of the inner section of the outlet tube. Inone example, the upper rail or rail arrangement is an upper rail in asingle piece, having one gap therein. In a second embodiment, the upperrail or rail arrangement comprises two, arcuate, rail sections separatedby two gaps.

Also in an example shown, the second end piece includes a second axialprojection thereon, on an opposite side of the second end piece from themedia pack. The second end axial projection includes a second sealsupport thereon, with a second seal member mounted on the second sealsupport and positioned for sealing engagement with appropriatestructure, for example the internal sealing flange of the bowl orhousing bottom, i.e. to surround and define a liquid drain outlet.

In general terms, the housing and filter cartridge are configured suchthat: crankcase ventilation gases directed into the housing are directedinto an annular region inside the housing and around the filtercartridge; then through the media to the central interior; thenoutwardly from the filter cartridge through the first end piece; theninto the inner section of the outlet tube; and, then outwardly from thefilter assembly. In addition, the housing and filter cartridge areconfigured such that liquid coalesced within the media pack can drain tothe liquid drain, through the liquid drain and outwardly from the filterassembly.

In an example depicted, as the crankcase ventilation gases are directedinto the housing, they are directed into a volume between internal andexternal flanges of a cover assembly, before being directed into anannular region inside the housing, and around the filter cartridge.

In an example shown and described, the filter cartridge includes a checkvalve therein comprising a valve member and first and second valveseats. The valve member can comprise a ball, positioned within the openfilter interior. In a typical arrangement, the crankcase ventilationfilter assembly includes a support positioned within open filterinterior, with the ball positioned therein.

In such arrangements, the first valve seat is positioned adjacent to thefirst end piece. The valve member, when positioned against the firstvalve seat, closes the valve seat to flow of liquid therethrough. Bythis is not necessarily meant that the valve seat is fully “sealed” butrather that liquid flow through the first valve seat is substantiallyinhibited. The first valve seat would typically be located in the firstend piece. Thus the valve member (i.e. the valve ball) would not restagainst the first valve seat unless a vehicle having the crankcaseventilation filter assembly mounted thereon, had flipped (rollover). Asa result of the construction described, the check valve assemblyprotects the engine against liquid draining therein, in a rollovercondition.

The second valve seat is positioned adjacent the second end piece; and,the valve member when positioned against the second valve seat, does notclose the second valve seat to liquid flow therethrough. This would be anormal condition for the assembly, in use with an engine operating. Thevalve member, typically a valve ball, rests on the second valve seat.This does not, however, close the valve seat to drain of liquidtherethrough, during normal operation.

In one example, the crankcase ventilation assembly is configured suchthat the upper rail of the framework is c-shaped (arcuate shaped), andincludes a single gap therethrough, although alternatives are possible.When the upper rail is c-shaped with a single gap therethrough, the gaptypically has an arcuate extension of no more than 60° and least 20°,typically within the range of 30°-60°, inclusive. In an exampleembodiment in which the upper rail comprises two arcuate sections,spaced by two gaps, each gap is typically at least 20° and not more than60°.

In an example described, the first end piece of the filter cartridgeincludes an outer periphery with a plurality of spaced, radiallyoutwardly projecting, projections thereon.

In an example assembly, the cover assembly includes an outer flange witha shoulder positioned above, typically pressing against, these, spaced,radially outwardly projecting, projections, on the first end piece. Thishelps secure the cartridge in operating position.

In another example, the second end piece of the filter cartridge isgenerally circular, except it has one straight, truncated, sectiontherein.

Other features described and shown herein relate to a regulation valveassembly in the cover assembly; and, a relief assembly in the coverassembly. Further, a projection arrangement from the second end piece ofthe cartridge, positioned to engage an upward projection arrangement ona bottom of the bowl, is described.

In another aspect of the present disclosure, a filter cartridge for usein a crankcase ventilation filtration arrangement is described. Thefilter cartridge comprises a media pack surrounding an open filterinterior, a central media support tube surrounded by the media pack,first and second seal members, and first and second end piecespositioned with the media pack therebetween. In example described, thecentral media support tube and first and second end pieces compriseportions of a single integral molded piece.

In a typical example filter cartridge, the second end piece has an outerperimeter and includes a central aperture therethrough in communicationwith the open filter interior. Further, the second end piece includes asecond seal support thereon projecting in a direction away from thefirst end piece. The second seal support on the second end piecesupports the second seal member for sealing at a location: spaced acrossthe second end piece at least 20% of a distance across the second endpiece from the outer perimeter toward the central recess. Further, it istypically spaced at least 20% of a distance across the second end piecefrom the central aperture toward the outer perimeter. (Usually it isalso spaced in overlap with the media pack at least 20% across the mediapack from both inner and outer edges of the media pack).

In a typical example, the second end piece is an end piece of the filtercartridge directed downwardly, in typical use.

Also in a typical example filter cartridge arrangement according to anaspect described herein, the first end piece includes a first axialprojection thereon, extending in a direction away from the second endpiece. The first end piece includes an outer perimeter and a centralaperture. The first axial projection includes a base section with afirst seal member mounted thereon: i.e. the base section operates as aseal support. Further, first axial projection includes a frameworkhaving a rail arrangement and rail support arrangement. The railarrangement and rail support arrangement are typically positioned tosupport the seal arrangement spaced across the first end piece from theouter perimeter a distance corresponding at least 20% of the distancefrom the outer perimeter toward the central aperture. Further, the sealarrangement on the first partial projection is analogously positioned Inaddition, the rail arrangement and rail support arrangements aretypically positioned at least 20% of the distance across the first endpiece from the central aperture toward the outer perimeter. Further, theseal support is typically is analogously positioned. Also, typicallyeach of the support and seal are positioned in overlap with the mediapack at a location spaced across the media pack at least 20% (of adistance across the media pack) from both inner and outer edges of themedia pack.

In one arrangement, a rail member of the framework has a c-shape,usually with a single gap therein (at an open end of the c). In example,the gap in the c-shape extends over a radial arc of at least 20°,usually not more than 60° and often within the range of 30°-60°,inclusive. In a second embodiment, the rail or rail arrangementcomprises two arcuate rail sections, spaced by two gaps; each gap beingat least 20° and typically not more than 60°.

In examples described, the second end piece includes a drain aperturearrangement therethrough, in direct drain overlap with an end of themedia pack. Typically the drain aperture arrangement includes one ormore drain apertures each of which is positioned spaced from an outerperimeter of the second piece by at least 40% of the distance from theouter perimeter of the second end piece toward the central aperture ofthe second end cap; and in overlap with the media pack at least 40%thereacross from an outer edge toward an outer edge. In a typicalexample in which the assembly includes a support tube, the drainaperture arrangement can comprise one or more apertures adjacent to, andgenerally radially outwardly from, the support tube. In examples shown,the portion of support tube adjacent to which the aperture arrangementis positioned, is an impermeable section of the support tube.

In example filter cartridge arrangements described, the second end piecewill be orientated directed downwardly during normal installation. Thesecond end piece can further include a projection arrangement thereon,directed downwardly, for example in the form of hook or snap fitmembers.

In an example, the filter cartridge further includes a check valvetherein, comprising a first valve seat, a second valve seat and a valvemember. The second valve seat is typically adjacent to the second endpiece and the first valve seat is typically adjacent to the first endpiece. The valve member is typically oriented to close the first valveseat to passage of liquid therethrough, when positioned thereagainst;and, to not close the first valve seat, when positioned thereagainst. Inoperation of the assembly, the check valve arrangement operates toprovide some roll over protection to the engine, when the assembly isinstalled. In an example described, the valve member is a ball. Further,the first valve seat typically comprises a end member snap fit to thecentral aperture of the first end piece.

In another aspect to the present disclosure, a filter cartridge forcrankcase ventilation filtration is provided. The filter cartridgecomprises a media surrounding an open filter interior, and furtherincludes a central media support tube surrounded by the media pack andhaving first and second ends. First and second end pieces are positionedwith the media pack therebetween. The first and second end pieces can beformed integral with a central media support. A check valve arrangementis included in the filter cartridge, having a first valve seat, a secondvalve seat and a valve member. The first valve seat is positionedadjacent to a first end of the central media support tube, the secondvalve is positioned adjacent to a second end of the central mediasupport tube and the valve member is positioned within the central mediasupport tube. The valve member is configured and positioned in a mannerremovably between the first and second valve seats. The first valve seatis configured so that when the valve member is seated thereto, the valveseat is closed to flow of liquid therethrough. Further, the second valveseat is configured so that when the valve member is seated thereto, thesecond valve seat is not closed to the passage of liquid therethrough.When oriented in this manner, the check valve arrangement operates toprotect the vehicle during rollover, from liquid draining thereto fromthe filter cartridge.

In a typical example, the valve may compromise a ball. Also in a typicalexample, the first valve seat comprises a seat member snap fit to thefirst end piece.

In a another aspect to the present invention, a crankcase ventilationfilter assembly is provided. The assembly comprises a housing having aninterior, for example, defining a bowl (housing base) and a coverassembly. The cover assembly includes an air flow outlet tube, includingan inner section; an optional air flow inlet tube; an internal flange;and, and an external flange. Typically the bowl (housing base) definesan interior and is releasably secured to the cover assembly, for examplewith a threaded arrangement. The bowl (housing base) includes a bottomwith a liquid drain surrounded by an internal flange. The air flow inletcan be positioned in an alternate location form the cover assembly.

A filter cartridge as previously described can be operably positioned inthe housing interior with first valve seat adjacent from the coverassembly; and, with a second valve seat remote from the cover assembly.

It is noted that a number of additional specific example features aredescribed herein, for use in association with assemblies and componentsas characterized. It is further noted that an arrangement does not needto include all of the features characterized herein, to obtain someadvantage according the present disclosure. Methods of use are alsodescribed.

1. A filter cartridge, for crankcase ventilation filtration, comprising:(a) a media pack surrounding an open filter interior; (b) a centralmedia support tube surrounded by the media pack; (c) first and secondseal members; and, (d) first and second end pieces positioned with themedia pack therebetween; (i) the first end piece including a first axialprojection thereon extending in a direction away from the second endpiece; (A) the first end piece including an outer perimeter and acentral aperture; (B) the first axial projection including a basesection with the first seal member thereon; and, (C) the first axialprojection including a projection extending from adjacent the first sealmember in a direction away from the base section; (ii) the second endpiece having an outer perimeter and including a central aperturetherethrough in communication with the open filter interior; (iii) thesecond end piece including a second seal support thereon projecting in adirection away from the first end piece; the second seal support on thesecond end piece supporting the second seal member; and, (iv) the firstseal member being mounted on the first seal support for radiallyoutwardly directed sealing engagement with a surrounding portion of anassembly in use; (A) the first seal member having a different outerdimension from each of an outer perimeter and an inner perimeter of themedia pack; and, (v) the second seal member being mounted on the secondseal support in an orientation for radially outwardly directed sealingengagement with a surrounding portion of an assembly, in use; (A) thesecond seal member having a different outer dimension from each of anouter perimeter and an inner perimeter of the media pack; and, (B) thesecond seal member having a different outer perimeter than the firstseal member.
 2. A crankcase ventilation filter cartridge according toclaim 1 wherein: (a) the second seal support on the second end piecesupports the second seal member at a location in axial overlap with themedia pack.
 3. A crankcase ventilation filter cartridge according toclaim 2 wherein: (a) the second seal support on the second end piecesupports the second seal member at a location spaced across the secondend piece at least 20% of a distance across the second end piece fromthe outer perimeter of the second end piece toward the central aperture.4. A crankcase ventilation filter cartridge according to claim 3wherein: (a) the second seal support on the second end piece supportsthe seal member at a location spaced across the second end piece atleast 20% of a distance across the second end piece from the centralaperture toward the outer perimeter.
 5. A crankcase ventilation filtercartridge according to claim 3 wherein: (a) the first seal support onthe first end piece supports the first seal member at a location inaxial overlap with the media pack.
 6. A crankcase ventilation filtercartridge according to claim 5 wherein: (a) the first seal support onthe first end piece supports the seal member at a location spaced acrossthe first end piece at least 20% of a distance across the first endpiece from the outer perimeter of the first end piece toward the centralaperture.
 7. An air filter cartridge according to claim 1 wherein: (a)the first axial projection includes a framework having a rail and a railsupport arrangement.
 8. A filter cartridge according to claim 7 wherein:(a) the rail has a shape with at least one opening therein extendingover a radial arc within the range of 30°-60°, inclusive.
 9. A filtercartridge according to claim 8 wherein: (a) the rail on the frameworkcomprises two arcuate sections spaced by two gaps.
 10. A filtercartridge according to claim 7 wherein: (a) the rail on the frameworkcomprises two arcuate sections spaced by two gaps.
 11. A filtercartridge according to claim 1 wherein: (a) the second end pieceincludes a drain aperture arrangement therethrough, in overlap with anend of the media pack.
 12. A filter cartridge according to claim 37wherein: (a) the drain aperture arrangement in the second end cap isspaced from the outer perimeter of the second end piece at least 40% ofa distance from an outer perimeter of the second end piece toward acentral aperture of the second end piece.
 13. An air filter cartridgeaccording to claim 1 wherein: (a) the first seal member has a smallerouter dimension than an outer perimeter of the media pack.
 14. An airfilter cartridge according to claim 13 wherein: (a) the second sealmember has a smaller outer dimension than an outer perimeter of themedia pack.
 15. An air filter cartridge according to claim 1 wherein:(a) the second seal member has a smaller dimension than an outerperimeter of the media pack.
 16. A crankcase ventilation filter assemblyaccording to claim 1 wherein: (a) the second end piece of the filtercartridge includes an outer periphery with a plurality of spaced,radially outwardly projecting, projections thereon.
 17. A crankcaseventilation filter assembly comprising: (a) a housing defining aninterior and including an air flow inlet and an air flow outlet; (i) thehousing including a cover assembly including: an air flow outlet tube,including an inner section; an internal flange; and, an external flange;and, (ii) the housing including a housing bottom section defining aninterior and being releasably secured to the cover assembly; the bottomsection including a bottom with a liquid drain surrounded by an internalseal flange; and, (b) a filter cartridge separate from the housing andremovably positioned within the housing interior; the filter cartridgecomprising: (i) a media pack surrounding an open filter interior; (ii) acentral media support tube surrounded by the media pack; (iii) first andsecond seal members; and, (iv) first and second end pieces positionedwith the media pack therebetween; (A) the first end piece including afirst axial projection thereon extending in a direction away from thesecond end piece; (1) the first end piece including an outer perimeterand central aperture; (2) the first axial projection including a basesection with the first seal member thereon; and, (3) the first axialprojection including a projection extending from adjacent the first sealmember in a direction away from the base section; (B) the second endpiece having an outer perimeter and including a central aperturetherethrough in communication with the open filter interior; (C) thesecond end piece including a second seal support thereon projecting in adirection away from the first end piece; the second seal support on thesecond end piece supporting the second seal member; and, (D) the firstseal member being mounted on the first seal support in radiallyoutwardly directed sealing engagement with the internal flange on thecover assembly; (1) the first seal member having a different outerdimension from each of an outer perimeter and an inner perimeter of themedia pack; and, (E) the second seal member being mounted on the secondseal support in radially outwardly directed sealing engagement with theinternal seal flange in the housing bottom; (1) the second seal memberhaving a different outer dimension from each of an outer perimeter andan inner perimeter of the media pack; and, (2) the second seal memberhaving a different outer perimeter than the first seal member.
 18. Acrankcase ventilation filter assembly according to claim 17 wherein: (a)the first seal member has a smaller outer dimension than an outerperimeter of the media pack.
 19. A crankcase ventilation filter assemblyaccording to claim 19 wherein: (a) the second seal member has a smallerouter dimension than an outer perimeter of the media pack.
 20. Acrankcase ventilation filter assembly comprising: (a) a housing definingan interior and including an air flow inlet and an air flow outlet; (i)the housing including a removable cover assembly; and, (ii) the housingincluding a housing bottom section defining an interior and beingsecured to the removable cover assembly; the bottom section including abottom with a liquid drain; and, (b) a filter cartridge separate fromthe housing and removably positioned within the housing interior; thefilter cartridge comprising: (i) a media pack surrounding an open filterinterior; (ii) a central media support tube surrounded by the mediapack; (iii) a first seal member; and, (iv) first and second end piecespositioned with the media pack therebetween; (A) the first end pieceincluding a first axial projection thereon extending in a direction awayfrom the second end piece; (1) the first end piece including an outerperimeter and central aperture; (2) the first axial projection includinga base section with the first seal member thereon; and, (3) the firstaxial projection including a projection extending from adjacent thefirst seal member in a direction away from the base section; the firstprojection including an end having a shape with at least a first openingtherein extending over a radial arc within the range of 30°-60°,inclusive; (B) the first seal member being mounted on the first sealsupport in radially outwardly directed sealing engagement with thehousing; and; (E) the housing including a tube having a portionextending through the first opening in the end of the first axialprojection.